Building panel

ABSTRACT

Disclosed is a panel for use in construction of buildings, barriers and other structures, the panel comprising an internal framing structure encased in a solidified aerated medium, the aerated medium having an impermeable external layer. The panel has insulative properties along with inherent strength, impact resistance, and load bearing capacity.

FIELD OF THE DISCLOSURE

The disclosure relates to a panel for building and construction of dwellings, shelters and other structures.

BACKGROUND OF THE DISCLOSURE

Known building methods are ordinarily reliant on an internal building framework and a secondary material which is affixed with the framework by use of mortar, nails, screws and/or bolts. Alternatively traditional building methods rely on a primary material stabilised by internal rods to provide support.

Current building panel systems utilise composite internal materials such as aerated polyurethane, cement and polystyrene, fibre and polystyrene to provide a panel. The panels provide a lightweight construction medium incorporating insulative properties for temperature and noise control and fire retardation. They also allow for cutting or shaping of the panel without compromising the inherent structure of the panel. However the building panels do not provide the inherent strength, impact resistance, and load bearing capacity of, for example, traditional building methods.

SUMMARY OF THE INVENTION

Disclosed in a first aspect is a building panel comprising: an internal framing structure encased in a solidified aerated medium, the aerated medium having an impermeable external layer.

In one form the panel includes one or more channels extending through the aerated medium.

In a second aspect, disclosed is a building panel comprising an internal framing structure encased in a solidified curable medium, with one or more channels extending through the curable medium.

In a third aspect, disclosed is a method of manufacturing a building panel, the method comprising aligning one or more elongate conduits with a framing structure; depositing a curable medium on the framing structure and around the one or more elongate conduits and allowing the curable resin to set.

In one form the curable medium is an aerated medium which solidifies to form a solid aerated medium.

In one form the method further comprises the step of depositing (eg by spraying) an impermeable external layer on outside the curable medium.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows a cut-out side elevation view of one embodiment of a building panel;

FIG. 2 is a lateral cross-sectional view of the building panel of FIG. 1;

FIG. 3 is a lateral cross-sectional view of a second embodiment of the building panel;

FIG. 4 is a lateral cross-sectional view of a third embodiment of the building panel;

FIG. 5 is a cut away side elevation view of a fourth embodiment of the building panel;

FIG. 6 is a cut away side elevation view of a fifth embodiment of the building panel;

FIG. 7 is a lateral cross-sectional view of the building panel of FIG. 6;

FIG. 8 is a lateral cross-sectional view of a sixth embodiment of the building panel;

FIG. 9 is a lateral cross-sectional view of a seventh embodiment of the building panel.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

Referring to FIGS. 1 and 2, disclosed is a building panel 1 comprising an internal framing structure 2 surrounded by a solidified aerated medium 3 making up an internal core. The internal framing structure 2 is composed of natural or man-made materials or a combination of both. The internal framing structure 2 may be composed of wood, extruded metals, laminated metals, high-tensile plastic, poltruded fibreglass or any other natural or man-made material. The internal framing structure 2 is surrounded by a solidified aerated medium 3. The solidified aerated medium 3 is composed of aerated polyurethane, aerated polyethylene, or any other solidified aerated medium that permits the entrapment of air while forming a solid.

The solidified aerated medium 3 is capable of having a hard impermeable external layer 4. For example, the impermeable external layer 4 comprises a sheet of fibreglass. The impermeable external layer 4 is capable of direct exposure to natural elements without any further topical treatment and has the capacity to be moulded in the manufacturing process to provide building finishers. Further the impermeable external layer 4 provides a medium for bonding, pressing, stamping or otherwise coating, affixing or cladding the external surface of the building panel.

The internal framing structure 2 extends across the full dimensions of the building panel and is designed to provide overall structural integrity, strength, and impact resistance to the building panel 1.

The building panel 1 further comprises utility channels 5 which extend through the building panel 1. The utility channels 5 comprise elongate piping which is sized to allow wiring, plumbing and other utilities to extend through the building panel 1. The elongate piping may be composed of plastic or lightweight metal or any other suitable building material.

The solidified aerated medium 2 has dense celluline characteristics and is designed to encase the internal framing structure 2 and provide insulative properties with relation to temperature, sound, and fire retardation. The impermeable external layer 4 provides a finished surface or a surface capable of holding secondary commercial cladding materials (not illustrated).

It can be seen that for construction, the building panel 1 will be capable of being cut to meet construction requirements without compromising the structural integrity of the building panel 1.

Turning to FIG. 3, the building panel 1 is shown with an external commercial cladding material 7 bonded or affixed to the impermeable external layer 4 of the building panel 1.

Turning to FIG. 4 the building panel 1 is shown with a pre-moulded external layer 4 a. In FIG. 4 the pre-moulded external layer 4 a is a corrugated mould for roofing applications.

Referring to FIG. 5, the building panel 1 can further comprise an additional internal secondary framing structure 8 embedded over the primary framing structure. The secondary framing structure 8 provides increased impact stabilisation which is useful in roof or floor applications. The secondary framing structure 8 is embedded over the framing structure 2 and the solidified aerated internal medium 3.

Referring to FIG. 6, disclosed is a building panel comprising a solidified aerated internal core 13 and an impermeable external layer 14. The impermeable external layer 14 is composed of a solidified medium which is similar or identical to the solidified aerated internal medium 13. For example the solidified aerated internal medium could be poltruded fibreglass while the impermeable external layer 14 is a sheet of fibreglass. As seen in FIGS. 7 and 8 the building panel 11 of FIG. 6 can further incorporate a secondary commercial cladding material 15 which is bonded, affixed or otherwise attached to the impermeable external layer 14 of the building panel 11. Further, as shown in FIG. 9, the external layer 14 b can be pre-moulded. In FIG. 9 the external layer 14 b is pre-moulded in a corrugated mould for roofing applications.

In a further embodiment of the present invention disclosed is a method of manufacturing a building panel 1. The method of manufacture comprises aligning one or more elongated pipes 5 with a framing structure 2. The elongate pipes 5 are aligned such that they extend through the building panel 1 to allow utility services such as wiring and pluming to extend through the building panel 1. A curable medium such as the solidified aerated medium of 3 is deposited on the framing structure 2. The curable medium is allowed to set encasing the framing structure 2 with the curable medium 3 to form a building panel 1. The curable medium solidifies to form a solid aerated medium.

An impermeable external layer 4 is deposited outside the curable medium 3. In one example the curable medium 3 comprises poltruded fibreglass while the impermeable external layer comprises fibreglass sheeting which is deposited over the curable medium 3.

The building panel 1 provides inherent strength, impact resistance, and load bearing capacity while providing a lightweight construction medium incorporating insulative qualities for both temperature and noise control and fire retardation. Further the building panel 1 has an aesthetic appearance and allows for cutting and shaping of the building panel without compromising the inherent strength of the building panel.

Although the invention has been described with reference to particular embodiments, it would be appreciated by those skilled in the art that the invention may be embodied in many other forms.

In the preceding description and in the claims which follow, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” is used in an inclusive sense, ie. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments.

Variations and modifications can be made in respect of the system described above and defined in the following statements of claim. 

1. A building panel comprising: an internal framing structure encased in a solidified aerated medium, the aerated medium having an impermeable external layer.
 2. A building panel as defined in claim 1, further comprising one or more channels extending through the aerated medium.
 3. A building panel as defined in claim 2, wherein the channels are composed of elongate piping, sized to allow wiring, plumbing and other utilities to extend through the panel.
 4. A building panel as defined in claim 1, wherein the internal framing structure comprises one or more internal frames.
 5. A building panel comprising: an internal framing structure encased in a solidified curable medium, one or more channels extending through the curable medium.
 6. A building panel as defined in claim 5 wherein the channels are composed of elongate piping, sized to allow wiring, plumbing and other utilities to extend through the panel.
 7. A building panel as defined in claim 5, wherein the internal framing structure comprises one or more internal frames.
 8. A method of manufacturing a building panel, the method comprising: aligning one or more elongate conduits with a framing structure; depositing a curable medium on the framing structure; allowing the curable resin to set.
 9. A method of manufacturing a building panel as defined in claim 8, wherein the curable medium is an aerated medium which solidifies to form a solid aerated medium.
 10. A method of manufacturing a building panel as defined in claim 8, further comprising the step of depositing an impermeable external layer onto the curable medium.
 11. A method of manufacturing a building panel as defined in claim 10, wherein the step of depositing the impermeable external layer comprises depositing fiberglass sheeting over the curable resin. 